05 fi cal tool manual

7/29/2019 05 FI Cal Tool Manual

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Ninja ZX-6RRNinja ZX-10R

Kawasaki FI Calibration Tool

Instruction Manual


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IMPORTANT

This manual provides how to change the fuel injection amount, sub-throttleopening, and ignition timing of the racing ECU for the 2003 Ninja ZX-6RR, 2004

Ninja ZX-6RR/ZX-10R, and 2005 Ninja ZX-6RR/ZX-10R. This manual instructs

the dealing method briefly for the mechanic and being familiar with the personal

computer (PC).

As for the basic knowledge, refer to the base Service Manual for the Ninja

ZX-6RR and ZX-10R.

ZX600-K1: P/No. 99924-1311-01

ZX600-M1: P/No. 99924-1333-01

ZX600-N1: P/No. 99924-1346-01

ZX1000-C1/C2: P/No. 99924-1322-01/02

AFTER ANY MODIFICATION TO TUNE THE VEHICLE TO A COMPETITION

MACHINE, IT SHOULD NOT BE USED ON PUBLIC STREETS, ROADS OR

HIGHWAYS. THE USE OF THIS VEHICLE SHOULD BE LIMITED TO

PARTICIPATION IN SANCTIONED COMPETITION EVENTS UPON A

CLOSED COURSE.

2005 Kawasaki Heavy Industries, Ltd. First Edition (1) Jan. 24, 2005

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User License Agreement

For Kawasaki FI Calibration Tool

This User License Agreement ("AGREEMENT") is a legal agreement between you

(either an individual or a single entity) and Kawasaki Heavy Industries, Ltd., a Japanese

company, ("Kawasaki") for the Kawasaki FI Calibration Tool Software ("SOFTWARE").

By installing, copying, or otherwise using the SOFTWARE, you shall agree to be bound

by the terms of this AGREEMENT. If you will not agree to the terms of this AGREEMENT,

promptly uninstall the SOFTWARE and destroy all the SOFTWARE, including its COPY

if you have made one.

1. COPYRIGHT

All title and copyrights in and to the SOFTWARE (including but not limited to any

images, photographs, and text incorporated into the SOFTWARE) and the

accompanying printed materials are owned by Kawasaki and/or its licensor. The

SOFTWARE is protected by copyright laws and international treaty provisions.

2. GRANT OF LICENSE

(1) By purchasing the SOFTWARE, you are granted a license to use the

SOFTWARE under following conditions (2) and (3).

(2) USE: The SOFTWARE is licensed, not sold. You may install and use onecopy of the SOFTWARE on your computer.

(3) COPY: You may either (a) make one copy of the SOFTWARE solely for

backup or archival purposes or (b) install the SOFTWARE on a single

computer provided you keep the original solely for backup or archival

purposes. All title and copyrights in and to the COPY are also owned by

Kawasaki and/or its licensor, and you may not use the COPY for any

other purpose than to recover the SOFTWARE on your computer.

3. LIMITATIONS

You may not modify, reverse engineer, decompile, or disassemble the

SOFTWARE.

4. SOFTWARE TRANSFER

You may permanently transfer all of your rights under this AGREEMENT when the

recipient agrees to the terms of this AGREEMENT, provided you retain no copies,

you transfer all of the SOFTWARE and printed materials accompanied with it.

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5. TERMINATION

Without prejudice to any other rights, Kawasaki may terminate this AGREEMENT

if you fail to comply with the terms and conditions of this AGREEMENT. In such

event, you must uninstall the SOFTWARE and destroy all of the SOFTWARE,

including its COPY if you have made one.

6. LIMITED WARRANTY

(1) CUSTOMER REMEDIES: Kawasaki's and its suppliers entire liability and your

exclusive remedy shall be replacement of the SOFTWARE. This Limited

Warranty is void if failure of the SOFTWARE has resulted from accident, abuse

or misapplication

(2) NO OTHER WARRANTIES: To the maximum extent permitted by applicable law,

Kawasaki and its suppliers disclaim all other warranties, either express or

implied, including, but not limited to, implied warranties of merchantability and

fitness for a particular purpose, with regard to the SOFTWARE. This limited

warranty gives you specific legal rights. You may have others, which vary from

country, state or territory and jurisdiction to country, state or territory and

jurisdiction.

(3) NO LIABILITY FOR CONSEQUENTIAL DAMAGES INCLUDING PERSONAL

INJURY AND LOSS OF LIFE: To the maximum extent permitted by applicable

law, in no event shall Kawasaki or its suppliers be liable for any special,

incidental, indirect, or consequential damages including personal injury and loss

of life whatsoever (including, without limitation, damages for loss of business

profits, business interruption, loss of business information, or any other

pecuniary loss) arising out of the use of or inability to use the SOFTWARE, even

if Kawasaki has been advised of the possibility of such damages. Because some

countries, states or territories and jurisdictions do not allow exclusion or

limitation of liability for consequential or incidental damages, the above limitation

may not apply to you.

7. EXPORT LIMITATION

You shall agree not to export the SOFTWARE to foreign countries except for

complying with local laws and rules.

8. COMMERCIAL ARBITRATION

In case of trouble with the AGREEMENT, both parties assign Japan Commercial

Arbitration Association and under the rule thereof to settle a dispute and the

award thereof shall be final and binding upon both parties.

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Contents

1. KAWASAKI FI CALIBRATION TOOL OUTLINE ............................................. 6

1.1 SYSTEM FUNCTION ...................................................................................... 6

1.2 PERSONAL COMPUTER (PC) REQUIREMENT .................................................. 7

1.3 SYSTEM CONFIGURATION ............................................................................. 8

2. INSTALLATION PROCEDURE OF SETTING PROGRAM............................. 9

2.1 INSTALLING PROCEDURE .............................................................................. 9

2.2 FILE STRUCTURE ....................................................................................... 13

2.3 UNINSTALLING PROCEDURE ........................................................................ 14

3. OPERATING THE PROGRAM..................................................................... 16

3.1 STARTING.................................................................................................. 16

3.2 EACH MAP EDIT METHOD ........................................................................... 19

3.2.1 Map Edit............................................................................................ 19

3.2.2 Map Axis Edit .................................................................................... 23

3.2.3 Multi Map Edit ................................................................................... 25

3.2.4 Individual Value Edit.......................................................................... 27

3.3CHANGING ECU DATA................................................................................ 30

3.4 OTHER FUNCTIONS .................................................................................... 343.4.1 Monitoring Function........................................................................... 34

3.4.2 Data Edit during Engine Operation.................................................... 36

3.4.3 Title Editor (Memo)............................................................................ 36

3.4.4 Default Directory Setting Function..................................................... 37

3.5 FILE SAVING .............................................................................................. 37

3.6 CHANGING THE TARGET MACHINE ............................................................... 38

3.7 NEW USABLE FUNCTIONS........................................................................... 39

3.7.1 Plural Cells Data Selecting................................................................ 39

3.7.2 Plural Cells Data Copying ................................................................. 39

3.7.3 Plural Cells Data Changing Method .................................................. 40

4. MENU LIST .................................................................................................. 41

4.1 PULL DOWN MENU ..................................................................................... 41

4.1.1 File .................................................................................................... 41

4.1.2 Edit(E) ............................................................................................... 41

4.1.3 Monitor .............................................................................................. 41

4.1.4 Set..................................................................................................... 41

4.1.5 Window ............................................................................................. 42

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4.1.6 Help................................................................................................... 42

4.2 TOOL BAR (ICON)....................................................................................... 42

5. APPENDIX ................................................................................................... 43

5.1 CONNECTING METHOD ............................................................................... 435.1.1 05 ZX-6RR with Optional Meter and Racing Main Harness ............. 43

5.1.2 05 ZX-6RR with Original Meter and Standard Main Harness, Sub

harness ...................................................................................................... 44

5.1.3 05 ZX-10R with Racing Main Harness ............................................. 45

5.1.4 05 ZX-10R with Original Meter and Standard Main Harness............ 46

5.2 CAUTION ITEMS WHEN USING THE I/F BOX ................................................... 47

5.2.1 Caution when using the I/F Box ........................................................ 47

5.2.2 System Requirements of I/F Box....................................................... 47

5.2.3 Caution when communicating between Setting Tool and ECU.......... 47

5.3 TROUBLESHOOTING ................................................................................... 49

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1. Kawasaki FI Calibration Tool Outline

1.1 System FunctionKawasaki FI Calibration Tool is developed to modify the mapping of the racing

machine to gain operating conditions suitable for the course and the riders skill. The

following are the available setting functions.

Table 1 FI Tool Function

Model NameFunctions

AvailableSetting Range

03ZX-6R

R

04ZX-6R

R

04ZX-10

R

05ZX-6R

R

05ZX-10

R

1) Adjust the injected fuel rateat acceleration

-30 % ~ +30 % 2) Adjust the injected fuel rateof No.1 and No.4 cylinder

-30 % ~ +30 % 3) Adjust the injected fuel rateof No.2 and No.3 cylinder -30 % ~ +30 % 4) Adjust the injected fuel rateof primary and secondaryinjector*

-30 % ~ +30 %

-10 % ~ +10 %

--

--

--

--

--

--

--

--

5) Adjust the ignition timing -15CA~ +5CA 6) Adjust the sub-throttleopening angle

-50 % ~ +50 %-45 % ~ +45 %

--

--

--

--

--

7) Adjust the exhaust deviceopening angle

-50 % ~ +50 % -- -- -- 8) Adjust the all injected fuelrates of all operating area

simultaneously

-30 % ~ +30 %

9) Adjust the value of engineover revolution limiter

-1000 ~ +300 rpm0 ~ +400 rpm0 ~ +300 rpm

-1000 ~ +700rpm

------

--

----

--------

----

--

------

10) Set the fuel cut or not atdeceleration

Use or Not Use 11) Set the sub throttlecontrolled or not

Controlled orFull Open Fixed

-- --12) Set the exhaust devicecontrolled or not

Controlled orFull Open Fixed

-- -- 13) Set the Auto ShifterIgnition Cut Length

Controlled or not,

set Ig. Cut Time bygear range

-- -- -- -- 14) Set the Pit Road RPMLimit

Controlled or not,set Upper LimitRPM by gear range

-- -- -- -- Note: mark shows the model has the function.

Note: * +: primary injector rate down and secondary injector rate up.

-: primary injector rate up and secondary injector rate down.

Note: CA shows rotating angle of crankshaft.

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1.2 Personal Computer (PC) RequirementThe Kawasaki FI Calibration system operates on a Personal Computer (PC) having a

serial communication port with the racing electronic control unit (ECU) on the

motorcycle through an interface box (I/F Box).

Table 2 PC Requirement

Items Recommendation

Operating System Windows XP (US version, Japanese version)

CPU Pentium 150 MHz or faster

Memory 64 MB or more

Hard Disk Drive 2 MB or more of free space

Display Resolution 1024 x 768 pixels or more, more than 256 colors

Port Connector RS232C (D-sub 9 pin),

I/F Box cable can be connected to COM 1 ports

Other Equipped with a mouse or a pointer equivalent to mouse

NOTE

Even if the recommended PC is used, the Kawasaki FI Calibration Tool

program could not operate correctly depending on the other applications

installed to the PC.

If your PC does not equip 9-pin connector, use a suitable USB-RS232C adapter.

Some adapter cannot be communicated correctly depending on its

specification.

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1.3 System ConfigurationThe Kawasaki FI Calibration tool kit consists of (1) Racing ECU, (2) Racing Main

Harness or Standard Harness plus Racing Sub-harness, (3) I/F Box, and (4) Setting

Program. The Setting Program must be installed to your PC.

(4) Setting Program

installed to your PC(1) ECU

(3) I/F Box

Serial Cable

RS-232C 9P

Connector for

Tool Kit 6P

(2)

Harness

Fig. 1 Setting Tool Connection

Table 3 Setting Tool for 2005 Model

ZX-6RR ZX-10R

MeterType

OptionalMeter

Original MeterOptional

MeterOriginal Meter

(1) ECU Racing ECU P/No. 21175-0074 Racing ECU P/No. 21175-0073

(2) I/F Box Racing I/F Box: P/No. 26031-0025 or 26031-0240. Whichever is available

(3)Harness

Racing MainHarness26031-0325

RacingMain Harness26031-0326

Racing

Sub-harness26031-0327

plusStd. Main Harness

26031-1058

Racing MainHarness26031-0328

plus

Sub-harness26031-0307

Racing Main Harness26031-0328

plusSub-harness

26031-0308or

Racing Sub-harness26031-0244Plus

Std. Main Harness26031-1058

(4)Shift SW -- --

Contact type of SW can be used.Recommend the Shift Sensor made byBattle Factory or Dynajet.

(5) SettingProgram

CD or FD

NOTE: The detail of connecting method is shown in section 5.1.

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2. Installation Procedure of Setting Program

Program files will be supplied to users through Internet from kawasakidirect.

Download the Software Kawasaki FI Calibration. EXE to your PC and uncompress to

suitable folder

NOTE

Before installing the new Setting Program to the PC in which old version Program is

installed, save the old est files as back-up and then un-install the previous Program.

2.1 Installing Procedure(1) Execute Setup.exe to start the Setup program.

(2) Then the screen shown in Fig. 2 appears.

Fig. 2 Setting Screen of Setup Program

Click Next to install the Program. Click Cancel to stop installing procedure.

(3) The Product License Agreement screen shown in Fig. 3 appears.

Fig. 3 Product License Agreement

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Click Agree when you agree to the Product License Agreement. Click Not agree

when you do not agree to the Product License Agreement. Then the installing

procedure is stopped.

(4) Next the Serial Information screen shown in Fig. 4 appears.

Enter the information in both columns.

Fig. 4 User Information Registration / Authentication (Sample)

The Serial No is informed to you from the dealer.

The default settings ofUser Name and Serial No are vacant.

If you omit any of them, Next button is grayed out.

When the Serial No is wrong, an error message shown in Fig. 5 appears on the

screen. Input the correct Serial No in the column.

Fig. 5 Error Message

Click Next to install the Program. Click Cancel to stop the installing procedure.

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(5) The destination folder selection screen shown in Fig. 6.appears.

Fig. 6 Choosing Destination Folder

Choose the destination folder. The default setting is C:Program FilesRACEFI-Tool.

If you want to install the Program to another folder, click the Browse button to

display the Choose Folderscreen shown in Fig. 7. Then choose the folder.

Fig. 7 Choose Folder Screen

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Click Install to start the installing procedure. Click Cancel to stop the installing

procedure.

(6) After the Kawasaki FI Calibration Tool program is installed, the Setup finish

screen shown in Fig. 8 appears.

Fig. 8 Setup Finish Screen

If the destination folder has a file that has the same name of the file to be copied andwhose time stamp is newer than that for the file to be copied, the message screen

shown in Fig. 9 appears and the file cannot be copied. However, the installing

procedure is normally finished because the destination folder has the new data file

with newer time stamp.

Fig. 9 Message Dialog when overwriting was not performed

(7) Click OK button to finish the setup. After the setup is finished, the shortcut icon for

Kawasaki FI Calibration Tool program is registered on both the Desktop and the

Start Menu.

Click Cancel during the setup operation to quit the setup.

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2.2 File Structure Files to be copied into a destination folder

FI_Tool.exe

FI_Tool.bmp

FI_Tool FC.bmp

MCN_LIST.DAT

Setup.exe

Program file

256-color splash screen file

Full-color splash screen file

Uninstall file for execution

Files to be copied into the ZX600K folder under the destination folder.

FI_Tool.ini

FI_Tool.stz

Setting file for FI_Tool.exe of ZX600K

ZX600K Configuration File

Files to be copied into the ZX600K Work Folder

Standard_data.est Data file for only ZX600K

Files to be copied into the ZX600M folder under the destination folder.

FI_Tool.ini

FI_Tool.stz

Setting file for FI_Tool.exe of ZX600M

ZX600M Configuration File

Files to be copied into the ZX600M Work Folder

Standard_data.est Data file for only ZX600M

Files to be copied into the ZXT00C folder under the destination folder.

FI_Tool.ini

FI_Tool.stz

Setting file for FI_Tool.exe of ZXT00C

ZXT00C Configuration File

Files to be copied into the ZXT00C Work Folder

Standard_data.est Data file for only ZXT00C

Files to be copied into the ZX600N folder under the destination folder.

FI_Tool.ini

FI_Tool.stz

Setting file for FI_Tool.exe of ZX600N

ZX600N Configuration File Files to be copied into the ZX600N Work Folder

Standard_data.est Data file for only ZX600N

Files to be copied into the ZXT00C2 folder under the destination folder.

FI_Tool.ini

FI_Tool.stz

Setting file for FI_Tool.exe of ZXT00C2

ZXT00C2 Configuration File

Files to be copied into the ZXT00C2 Work Folder

Standard_data.est Data file for only ZXT00C2

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2.3 Uninstalling ProcedureUninstalling operation can be executed on the Add/Remove service application in

the Control Panel.

(1) Open the Control Panel screen from My ComputerorExplorerscreen.

Fig. 10 Control Panel Screen

Then click the Add/Remove icon.

(2) Add/Remove Programs Properties screen appears.

Fig. 11 Add/Remove Programs Properties screen

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Click FI Calibration Tool and then click Add/Remove to start the Setup program.

(3) The screen shown in Fig. 12 appears.

Fig. 12 Uninstall Starting Screen

ClickYes to start the uninstalling procedure.

(4) After the uninstallation is completed, Uninstall Completion screen shown in Fig. 13

appears.

Fig. 13 Uninstall Completion Screen

If you tried to delete the program but you couldnt do it due to some reason (ex. the

program is starting), the message shown in Fig. 14 appears. In such case, delete

the files remaining in the screen folder by yourself.

Fig. 14 Message Dialog when some files were not deleted

(3) Click OK button to complete the uninstalling procedure.In this step, setup.exe is left in the FI Calibration Tool folder, but it will be deleted

when you start the PC next time.

NOTE

When restarting after uninstallation is finished, the DOS window may remain

open. (It occurs on Windows98.) At that time close the window by yourself.

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3. Operating the Program

3.1 Starting(1) Double-click the shortcut icon Kawasaki FI Calibration Tool on the Desktop screen

or click the Kawasaki FI Calibration Tool in Program Menu on Start Menu.

(2) Then Machine Select screen shown Fig. 15 appears.

Fig. 15 Machine Select Screen

Click the target machine name, then click OK button or press Enterkey.

If you want to stop, click Cancel button.

(3) The initial screen shown in Fig. 16 appears.

Pull down

File menu

Fig. 16Initial Screen

It starts to load the data file (EST file) to be edited on the initial screen.

Go to the pull-down File menu and select Open, or click the FileOpen icon (leftend) on the toolbar.

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(4) The Open dialog shown in Fig. 17 appears.

Fig. 17 Open Dialog

Click the data file to be edited in the Open dialog screen. The selected data file

name is shown in the File name. Then click the Open button.

(4) The Menu dialog screen shown in Fig. 18 appears.

Fig. 18 Menu Dialog (in case of ZX1000-C2)

Select the mode to be edited in the Menu dialog.

The modes that can be used are as follows:

MODE (IN CASE OF ZX1000-C2)In this Mode you can edit the Compensations below.

Click one Label in the Menu dialog and click the OK button or Enter (Return)button, or double click one Label, to display the Map Edit screen.

Compensation for Acceleration: Regulates the rate of fuel injection at

acceleration

Comp. Map for Injection No.1: Regulate the rate of fuel injection at normal

operation (For the #1 and #4 cylinders)

Comp. Map for Injection No.2: Regulate the rate of fuel injection at normal

operation (For the #2 and #3 cylinders)

Comp. Map for Injection Rate: Regulate the rate of primary and secondary fuel

injection

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Comp. Map for Spark Advance: Regulate the ignition timing

Comp. Map for Sub Throttle: Regulate the sub-throttle opening

Comp.Map for Exhaust Valve: Regulate the exhaust valve opening

Pit Road Limit RPM (05 ZX-10R only): Regulate the pit road limit RPM

Auto Shifter Ignition Cut Length (05 ZX-10R only): Regulate the ignition cut

length at auto shifting

Extra Shift Indicate RPM (05 ZX-10R only): Regulate the shift indicate RPM

(for optional meter)

MODEIn this Mode you can edit the eight Values below.

Click the Constants list button to display the Setting Values Edit screen.

All Area Fuel Compensation Value: Regulate the rate of fuel injection for all

operating ranges

OverRev. shift Value: Regulate the off-set value from the standard OverRev

Limiter

Select Fuel Cut [Use: 0 / Not Use: 1]: Set the fuel-cut at deceleration

Select Sub-throttle [Controlled: 0 / Full Open Fixed: 1]:

Set the sub throttle control

Select Exhaust Valve [Controlled: 0 / Full Open Fixed :1]:

Set the exhaust valve control

Select Auto Shifter [Use: 0 / Not Use: 1]:

Set the auto shifter control.

Select Pit Road RPM Limit [Use: 0/ Not Use: 1]:

Set the pit road RPM limit control. 05 ZX-10R only

Select Extra Shift Indicator [Use: 0 / Not Use: 1]:

Set the shift indicator control. 05 ZX-10R only

Set when option meter is equipped.

Mode

Click the Data Exchange button in the Menu dialog to display the Data Exchange

screen. Click this button when you want to load the data in the ECU or write the edited

data in the ECU.

Mode

Click the Multi Map Edit button in the Menu dialog to display the Multi Map Edit

screen.

The Multi Map Edit can be used for the Comp. Map for Injection No.1 and No.2

and map edit for all cylinders can be carried out at the same time.

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3.2 Each Map Edit Method

3.2.1 Map Edit

Select one Label in the Menu dialog and click the OK button or the Enter(Return),

or double click one Label to display the Map Edit Screen shown in Fig. 19.

Fig. 19 Menu Dialog (in case of ZX600M)

In the Map Edit Screen, the Map to be edited will be displayed as the

two-dimensional graph (GRAPH) and the table (TABLE).

Cursor Point

Tool bar

Label

GRAPH

Area

Map switching button

1. Select point with mouse or arrow keys.

2. Move using mouse or arrow keys.

Z-axis: throttle

opening angle (%)

Map Z-axisswitching button

TABLE

Area

1. Select a cell by mouse or arrow keys mouse.

2. Input value or move the value by arrow key.

Fig. 20 Map Edit Screen (Compensation Map for Injection No.1 is shown as a

sample.)

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NOTE

If you closed the GRAPH or TABLE, open the Menu dialog on the Menu button of

the Tool bar and select the subject Map.

If you switched the subject Map using Map switching button, only the display

switches. When editing the subject Map, switch the Map by selecting the editing

point of the Graph or Table area of the subject Map.

Data Edit can be carried out either in the GRAPH orTABLE area and the editing

method for each area is as follows:

[Editing method on the GRAPH area]

Click a point on the graph to select the graph and the editing point of the engine

rpm that is the nearest position to the clicked point.

Drag & drop of the graph data: Press down the left button of the mouse to select

the editing point. After that, move the editing point up or down. Then, the data will

be changed to the possible setting value nearest to the release point.

(The direction of the engine rpm cannot be changed.)

Key allocation when a point on the line is selected

(or {Shift} + ): Switches the selected point to the right-side rpm

(or {Shift} + ): Switches the selected point to the left-side rpm

(or {Page Up}): Increases the graph data by an LSB* at the selected point

(or {Page Down}): Decreases the graph data by an LSB at the selectedpoint

{Shift} + (or {f2}): Switches the selected graph area (line number ) toanother (Active row is moved down in the TABLE)

{Shift} + (or {f3}): Switches the selected graph area (line number) toanother(Active row is moved up in the TABLE) LSB*:

Least Significant Bit

[Editing on the TABLE area]

Each value on the table can be directly edited by selecting the cell with mouse and

putting value by key strokes. The values in the data are always changed to the

nearest values that are possible to set. The values in the CPU are managed in

hexadecimal data.

Key allocation when a cell in the table is selected

{Shift} + : Switches the selected cell to the right-side rpm

{Shift} + : Switches the selected cell to the left-side rpm

{Shift} + : Switches the selected cell to the upper-side cell{Shift} + : Switches the selected cell to the lower-side cell

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{Page Up}: Increases the selected point by an LSB*

{Page Down}: Decreases the selected point by an LSB

{Enter}: Defines data

{Ctrl} + {Shift} + arrow: Switches the selected cells to the arrow direction

LSB means Least Significant Bit.

Line 6.3 is now selected.

Cursor PointLine 6.3 data

The Line on whichcursor exist is shownin bold.

Line 6.3

Cursor Point

Fig. 21 Map Edit Screen (Compensation Map for Injection No.1 is shown as a sample.)

The available setting value is restricted within the following ranges (in case of

ZX1000-C2).

Compensation for Acceleration: from -30 % to +30 %

Comp. Map for Injection rate and No.1/No.2: from -30 % to +30 %

Comp. Map for Spark Advance: from -15CA to +5CA*

Comp. Map for Sub Throttle: from -50% to +50%

Comp.Map for Exhaust Valve: from -50% to +50%

Pit Road RPM Limit: from 1000 to 5000 rpm, when pit road limit SW is ON.

Auto Shifter Ignition Cut Length: from 0 to 150 ms, when auto shifter control is

operated.

Extra Shift Indicate RPM: adjust the shift indicator lighting RPM within 10,000 and

15,000 rpm. This function is operated when the optional

meter is equipped.

*CA: crankshaft rotating angle.

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If a value out of the range is entered on the graph or table, the error message

shown in Fig. 22 will appear and the available maximum or minimum value will be

set.


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3.2.2 Map Axis Edit

In the TABLE area the axis data (Engine Revolution and Throttle Opening) can be

edited by keying in the data directly after selecting the cell by mouse or keystrokes.

The data is always exchanged to the nearest available setting value.

Axis data of Throttle Opening

Axis data of Engine Revolution

Fig. 23 Map Axis Editing (Original Axis Data)

Fig. 24 Map Axis Editing (Sample Screen After Changing the Axis Data)

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NOTE

The data of engine revolution must be set in a value always larger than the

left neighbor value and smaller than the right neighbor. If a value out of the

available range is input, the data will be rounded within the available range.

The data of throttle opening must be set in a value always larger than the

upper neighbor value and smaller than the lower neighbor. If a value out of

the available range is input, the data will be rounded within the available

range.

If a value out of the available range is input to both ends of the axis data, the

error message will appear and the maximum or minimum available setting

value will be set.

The axis data is applied to the all map simultaneously. Be caution that the

changed axis data is applied to other maps.

You cannot change the axis data at the Comp ensation for Acc elerat ion

screen.

When you move from an Axis Data cell of Throttle Opening to a cell of

adjusting data by key operation, the cell of the adjusting data line before

editing the Axis Data will be selected.

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3.2.3 Multi Map Edit

The Multi Map Edit can be used for the Comp. Map for Injection No.1 and No.2

and map edit for all cylinders can be carried out at the same time.

Click the Multi Map Edit button in the Menu dialog

Fig. 25 Menu Dialog Screen

Then the Multi Map Edit dialog shown in Fig. 26 appears.

Fig. 26 Multi Map Edit dialog

Click the OK button to display the Multi Map Edit screen. The method of Multi Map

Edit is the same as written above.

Quit the Multi Map Editing Mode

Click the Individual Edit button in the Multi Map Edit dialog to quit the Multi Map

editing mode and display the Map Edit screen set for the #1 Map.

Or, click a Map menu other than the Multi Map in the Menu dialog to display the Map

Edit screen for the selected Map.

Fig. 27 Multi Map Edit dialog

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CAUTION

Never edit the Multi Map setting by selecting the axis data in the

Table editing area, or the axis data could be broken and the

program could close.

NOTE

When selecting Multi Map editing mode, #2 Map data is overwritten with the

#1 Map data.

When both the Map area and Data area are closed in the Multi Map editing,

the Multi Map edit mode is automatically quitted.

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3.2.4 Individual Value Edit

In this Mode you can edit the four Values.

Click the Constants list button on the Menu Dialog to display the Setting Values

Edit screen.

Fig. 28 Menu Dialog Screen

Then Fig. 29 appears.

Decimal data entry and display screen

Move with shift key arrow key

Fig. 29 Edit Constants List Screen for ZX1000-C2

The editable items in the Constants List are as follows:

All Area Fuel Compensation Value: can be set in the range from 30 % to

+ 30 % (applied to all cylinders)

OverRev shift Value: set the off-set value from the standard Over Rev Limiter,

can be set in the range from 0 rpm to +300 rpm

Select Fuel Cut: set the Yes or Not of Fuel Cut at decreasing the speed

Select Exhaust Valve: set the Yes or Not of Exhaust Valve control

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The editable items in the Constants List are as follows:

All Area Fuel Compensation Value: can be set in the range from 30 % to

+ 30 % (applied to all cylinders)

OverRev shift Value: set the off-set value from the standard Over Rev Limiter,

can be set in the range from 1,000 rpm to +700 rpm

(ZX1000-C1 cannot be set this value.)

Select Fuel Cut: set the Yes or Not of Fuel Cut at decreasing the speed

Select Exhaust Valve: set the Yes or Not of Exhaust Valve control

Select Auto Shifter:set the Yes or Not of Auto Shifter control

(ZX1000-C2 only)

Select Pit Road RPM Limit:set the Yes or Not of Pit Road RPM control

(ZX1000-C2 only)

Select Extra Shift Indicator: set the Yes or Not of Extra Shift Indicator control

(ZX1000-C2 only)

Key allocation when a cell in the table is selected

{Shift} + : Switches the selected cell to the upper-side cell

{Shift} + : Switches the selected cell to the lower-side cell

{Page Up}: Increases the selected point by an LSB

{Page Down}: Decreases the selected point by an LSB

{Enter}: Defines the dataInput the value and press

Enter.

Fig. 30 Edit Constants List (Setting Data Sample)

The setting values are shown in a table and each value can be directly edited by

selecting the cell with mouse and putting value with keystrokes. The values in the data

are always changed to the values nearest available setting values.

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If a value out of the range is put in the table, the error message shown in Fig. 31 will

appear and the nearest available value will be set.


NOTE

The total Fuel Compensation Value is limited within -30% to +30% range of the

original setting for fuel injection quantity. If the total value of [All Area Fuel

Compensation Value] multiplies [Compensation for Acceleration] or [Comp. Map

for Injection No.1(No.2)] exceeds the limit, the total Fuel Compensation Value is

set to 30% or +30%.

[Example]

Comp. Map for Injection No.1 (or No. 2): 20% up

All Area Fuel Compensation Value: 30% up

1.20 x 1.30 = 1.56, 1.56 > 1.30

So, Total Compensation Value = 30 % upTotal Compensation Value 56 % up

When the Fuel Compensation Value is 0 %, the fuel injection quantity is controlled by

the Base Map. And the Base Map is calculated by water temperature, air temperature,

intake air pressure, throttle position, altitude pressure, and etc.

The intermediate values of the Map are calculated linearly.

CAUTION

When changing the Map, change the values gradually by checking the

engine condition or measuring the Air/Fuel ratio.

Always select Fuel Cut=0when your motorcycle is equipped with

catalyzer. If you failed, the muffler could burn out and break down.

When removing the exhaust valve actuator, set the Select Exhaust Valve

=1(Full Open Fixed)

(1) The Side Stand Switch function does not operate. Be caution at running

when equipping the side stand.

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3.3 Changing ECU DataThe racing ECU has two kinds of memory called ROM and RAM. So, there are two

data exchange methods.

ROM: Read Only Memory. Non-Volatile Memory.

The content in the memory is held even if the power source is turned off.

RAM: Random Access Memory. Volatile Memory.

The content in the memory is deleted when the power source is turned off.

The CPU can read the content from the memory and write content into the

memory.

(1) ROM data exchange:

All data can be exchanged collectively and it takes about one and a half minutes.

Even if the Ignition switch turns off the data will not be erased. But the data

cannot be exchanged when the engine is running.

(2) RAM data exchange:

The data can be exchanged when the engine is running, but the data is erased

when the Ignition switch turns off.

ECU

Temporary Memory

File

Data

Write/Read/Verify

Edit

Data

RAM

ROM

Personal Computer

Memory

Write Only (by shift + return operation)

Fig. 32 The Data Flow between ECU and PC

Click the Data Exchange button in the Menu dialog

Fig. 33 Menu Dialog

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Then the Data Exchange screen shown in Fig. 34 appears.

Fig. 34 Data Exchange Screen

In the Data Exchange screen, you can read, write and verify the data among the

ECU data edit data and file data.

The operation contents are shown on the screen step by step.

Fig. 35 Data Exchange Screen

The use and operation for each button is as follows:

[Read]

Click this button to read the data into the PC memory. (Essential operation)

You can read data from the following three data sources:

Read from

ECU Data: read the ECU data into the PC memory (when Monitor is in the Start

condition, the display is grayed out.)

Edit Data: read the editing data into the PC memory

File Data: read the (*.EST) data into the PC memory

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[Write]

Click this button to write the read data of the PC operating memory into the ECU or

memory in PC. At this time it is necessary that ignition switch is ON but engine is not

running.

Write Data

ECU: write the data into ECU (when Monitor is in the Start condition, the display

is grayed out.)

Edit: write the data into the editing area as editing data

NOTE

After writing the data into the ECU, confirm the data to be written in is the

same with the data in the ECU by using the Verifyfunction. The data may be

written into the ECU incorrectly according to the communication conditions.

The usable number of writing into the ECU is 65,500 times. If it exceeds the

limited number, error message of NOT Writ ingwill appear. At that time

replace with a new one.

Be caution, if you selectEdit, the present editing data can be lost.

Write the data into ECU after confirming that the Ignition is turned on and the

fuel pump and sub throttle valve are stopping.

CAUTION

After writing the data into the ECU, wait until the fuel pumpand the sub throttle valve stops. Then execute next

operation or turn off the ignition switch.

[Verify]

Click this button to select the data to be compared with the read data.

Compare with :

ECU Data: (when Monitor is in the Start condition, the display is grayed out.)

Edit Data

File Data (*.EST)

When the read data is same as the selected data, Same appears on the status

indication area, and when they are different, Not same appears.

NOTE

Verify the data with the ECU data after confirming that the Ignition is turned

on and the fuel pump and sub throttle valve are stopping.

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CAUTION

After verifying the data, wait until the fuel pump and the sub

throttle valve stops. Then execute next operation or turn off

the ignition switch.

[Clear]

Click this button to clear the data exchange area on the PC.

[Close]

Click this button to finish the data change (clear the operating memory) and close the

Data Exchange screen.

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3.4 Other Functions

3.4.1 Monitoring Function

In this mode, the data inside the ECU can be displayed during engine operation.

Go to the pull down Monitormenu and select Monitoror click Monitor icon on the

toolbar. The Monitor dialog shown in Fig. 36 appears.

(This window can be resident)

Fig. 36 Monitor Dialog

Click Start key to start displaying. When display starts, the key name will change to

Stop. When the Stop key is pressed during exchange process, the key name willchange to Start.

Pressing Enterkey can change the screen from Monitor dialog screen to Main

Window.

To set the data inside the ECU, which can be monitored from the Monitor dialog, go to

the pull down Monitormenu and select Item set, or click Set Item icon on the toolbar.

After the dialog shown in Fig. 37 appears, select the item that you want to set.

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Add/delete the items to be output on the monitor display

Items to be output on the monitorItems list

Fig. 37 Item Setting Dialog

Setting Monitor dialog items

>>[A]: Add items selected from the list to the Monitor Dialog Item area


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Pit Road SW [OFF:0/ON:1]: Condition of Pit Road RPM Limit SW at monitoring

When Select Pit Road RPM Limit is set 0 (Used), you can monitor.

(ZX1000-C2 only)

Shifter SW [OFF:0/ON:1]: Condition of Shifter SW at monitoring

When Select Auto Shifter is set 0 (Used), you can monitor.

(ZX1000-C2 only)

3.4.2 Data Edit during Engine Operation

You can reflect the Map and edit contents for each setting in the ECU during engine

operation.

Data editing method is the same as shown above.

[Exchanging edit data during engine operation]

After data editing, press the Shift + Return keys to reflect the edit data in ECU.

NOTE

Data can be communicated to the ECU by one point (cell).

The reflected data is effective only during engine operation. (It cannot be saved in

the ECU.) Be sure to save the edit data.

Map Axis data cannot be edited. When editing Map Axis data, use the Data

Exchange function.

3.4.3 Title Editor (Memo)

You can record the title (memo) for each edit data.

Go to the pull-down Set menu to select Title. The Title Editor dialog appears.

You can set the mode with the mouse and directly edit the data with keystroke.

Fig. 38 Title Editor Dialog

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3.4.4 Default Directory Setting Function

In this mode, you can set the default folder when File Open is carried out.

Go to the pull down Set menu to select Directory. The Directory dialog shown in Fig. 39

appears.

Directly enter the folder name by keystroke or use the Browsing function in the folder

search dialog to select the folder from the existing folders.

Use the full path name to write in the File Path.

Fig. 39 Directory Dialog

3.5 File SavingYou can save the data.

After editing the Map, click File and next click Save.button

Put the name in the column and then click the Save button.

NOTE The file extension is .est. When saving the extension is attached automatically.

If you change the extension, you cannot open the file.

When saving the data you can record the title (memo). Refer the 3.4.3 section.

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3.6 Changing the Target MachineYou can change the editing data according to the target machine. To change the

target machine, go to the pull down Set menu and select Machine Select. Then the

dialog shown in Fig. 40 appears.

Fig. 40 Machine Select Dialog

After you select the machine that you want to set by mouse operation or key

operation, click OK button or press Enter (Return) key. Then the machine change

confirming dialog shown Fig. 41 appears.

Fig. 41 Machine Change Confirming dialog

Clicking OK button or pressing Enterkey can change the target machine from next

starting.

NOTE

Selecting Cancel button in the Fig. 40 or Fig. 41 cannot execute the machine

changing.

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3.7 New Usable Functions

3.7.1 Plural Cells Data Selecting

You can select the plural cells. This is useful when copying the data to excel file or

changing the data simultaneously. (See Fig. 42).

Select the start point [Click (Left button)], and select the end point [{Shift} + Click

(Left button)] or [{Shift} + {Ctrl} + arrow key]

1. Click Left button

2. {Shift} + Click Left button

or {Shift} + {Ctrl} + arrow key

Fig. 42 Data Selecting Method

3.7.2 Plural Cells Data Copying

You can copy the selected data to Microsoft Excel file by using Microsoft Windowsclipboard.

Copy: {Ctrl} + {C} or [Pull down menu] [Edit] [Copy]

Paste: {Ctrl} + {V} or [Pull down menu] [Edit] [Paste]

FI Calibration Tool

Microsoft Excel sheet

Copy: {Ctrl} + {C}

Paste: {Ctrl} + {V}

Fig. 43 Data Copying Method

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3.7.3 Plural Cells Data Changing Method

You can change the value of plural cells simultaneously.

Directly input the value + {Enter} or press {Page Up} / {Page Down} key.

One {Page Up} increases 0.78 points and one {Page Down} decreases 0.78 points.

input value, ex.(5) + {Enter}.

or {PageUp} / {PageDown}

FI Calibration Tool

Fig. 44 Data Changing Method

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4. Menu List

4.1 Pull down Menu

4.1.1 File

Open Ctrl + O Loads data file

Close Closes the loaded file.

Save Names the file and saves it.

Menu F1 Displays the Menu dialog.

Exit Alt + F4 Finishes FI_Tool

4.1.2 Edit(E)

Undo Ctrl + Z Cancels the data edit.

Copy Ctrl + C Temporarily saves the data in cell(s) into clipboard

Paste Ctrl + V Paste the data in the clipboard.

Multi Map Edit Displays the Multi Map Edit setting dialog.

Individual Edit Finishes the Multi Map Edit.

4.1.3 Monitor

Monitor Displays the Monitor dialog.

Start Starts the Monitor Exchange

Stop Finishes the Monitor Exchange

Item set Displays the Monitor Item Setting Dialog

4.1.4 Set

RS232C Displays the RS232C setting dialog

Title Displays the Title setting dialog

Constants list Displays the Constants list setting dialog

Data Exchange Displays the Data Exchange setting dialog

Directory Displays the Directory setting dialog

Machine Select Displays the Machine Select dialog

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4.1.5 Window

Open Opens Map or Table window

Cascade Cascades two or more windows

Title Titles two or more windows

All Switches the graph mode on the Map screen

between All and Single

Monitor Dialog Moves the cursor to the Monitor dialog

MAP-***** Displays the active windows list

TABLE-***** Displays the active windows list

4.1.6 Help

Tool box Displays the tool box dialogAbout Kawasaki FI

Calibration Tool

Displays the Version dialog.

4.2 Tool Bar (Icon)

Fig. 45 Tool Box Dialog

Explanation from the left side

y Open the file (File - Open)

y Save the file (File - Save)

y Open the Menu dialog (File - Menu)

y Copy (Edit - Copy)

y Paste (Edit - Paste)

y Undo (Edit - Undo)

y Open the multi edit dialog (Edit - Multi Map Edit)

y Open the Monitor dialog (Monitor - Monitor)

y Open the Set Monitor Data dialog (Monitor - Item set)

y Open the Data Exchange dialog (Set - Data Exchange)

y Open the Constants list dialog (Set - Constants list)

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5. Appendix

5.1 Connecting Method

5.1.1 05 ZX-6RR with Optional Meter and Racing Main Harness

When installing the Racing Main Harness, refer the Race Kit Manual of ZX600-N1 (P/No.

99929-1868-01).

Fig. 46 Connecting Method

(1) Replace the ECU with Racing ECU.(2) Replace the Standard Main Harness with Racing Main Harness.

(3) Connect the connector of I/F Box to the connecting port [2] of ECU [1].

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5.1.2 05 ZX-6RR with Original Meter and Standard Main Harness, Sub

harness

(1) Replace the ECU with Racing ECU.

(2) Connect the Sub-harness connectors to the diagnosis line of Main Harness.

(3) Insert the two leads of Sub-harness to the ECU connector as shown.

ECU

Racing Sub harness

Standard main Harness

I/F Box harness

Connect Sub-harness to the

diagnosis line of Main Harness.

White/Green lead of Sub-harness Red lead of Sub-harness

Insert the White/Green leadInsert the Red lead


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(4) When inserting the leads, follow the method [A] and [B] shown below, or the

edge of the lead could damage the rubber seal inside connector.

Fig. 48 Inserting Method of Leads

5.1.3 05 ZX-10R with Racing Main Harness

Connecting method

(1) Remove the Standard Main Harness and install the Racing Main Harness (P/No.

26031-0328).

(2) Replace the standard ECU with Racing ECU (P/No. 21175-0073).

(3) Connect the 6-pin connector of I/F Box to the 6-pin connector of Racing Main

Harness

(4) Connect the 12-pin connector of Sub-harness* to the 12-pin connector of RacingMain Harness

* P/No. 26031-0307 is used for Optional Meter.

* P/No. 26031-0308 is used for Standard Meter.

(5) Connect other leads according to the ZX-10R Race Kit Manual (P/No. 99929-1870).

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5.1.4 05 ZX-10R with Original Meter and Standard Main Harness

When replacing the ECU, refer the Service Manual of ZX1000-C1/C2.

(1) Replace the original ECU with Racing ECU.

(2) Insert the Racing Sub-harness between Racing ECU and Standard Main Harness.

(3) Connect the connector of I/F Box to the connecting port of Racing Sub-harness.


1. ECU

2. Racing Sub-harness

3. Connect to the I/F Box.

4. Bullet Terminal

(4) Pull off the #22 pin (red/green lead) from the ECU connector of the Standard Main

Harness. ( mark shows the #22 pin, and X marks show no pin.)

Then install the bullet terminal in the packing of the Racing Sub-harness and connect

it to the bullet terminal of the Sub-harness.

Fig. 50 View from Main Harness Connector

(5) Connect the Pit Road RPM Limit SW to the Clutch SW connector and connect the

Shifter SW to the Side Stand SW connector. Refer the ZX-10R Race Kit Manual

(P/No. 99929-1870) to connect other leads.

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5.2 Caution Items when using the I/F Box

5.2.1 Caution when using the I/F Box

1. When connecting/detaching the I/F Box to/from the connector of the motorcycle,

keep the ignition switch turned off.

2. Do not use the I/F Box except setting usage of the motorcycle ECU..

3. Never connect the I/F Box with connectors other than the specified connectors.

4. Never run the motorcycle with I/F Box and the PC connected to the ECU.

5. Install the connector for the terminal protection in the motorcycle connector, except

when you connect the setting tool.

6. Never use the I/F Box near the place where a strong magnetic field, such as near

the televisions and the radios, is generated and static electricity is generated.

7. Do not touch the terminal of the I/F Box connector directly, and do not keep the I/FBox in the place where static electricity is generated.

5.2.2 System Requirements of I/F Box

(1) Rated Voltage: 12 V

(2) Operation Voltage: 8 ~16 V

(3) Ambient Temperature: 5 ~ 35C

5.2.3 Caution when communicating between Setting Tool and ECU

Confirm the serial communication port of PC before using the setting tool.

It is necessary to match the communication port of the setting tool with the PC side.

(1) Confirmation method of the communication port

Open the Property of the System and check the serial port in the device manager.

Correct serial port is COM1.

Fig. 51 Device Manager of System Property

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When ? mark or x mark is displayed on the COM1, the communication between

ECU and PC cannot be done.

Cancel the ? mark or x mark by referring the PC Instruction Manual or Help

function of the Windows.

(2) Setting Method of the Setting Tool

Select the RS232C in the toolbarSet of the Setting Tool.

When the Dialog is opened, select the Port on the PC side and click the OK button.

(If the communication port is COM1, select the Port1.)

(3) Connecting Method of Setting Tool

Personal com puter

D-sub

9P in

M otorcycle

Harness

I/F B ox

6Pin connector

To the serial

com m unications port

Fig. 52 Connecting Method of I/F Box

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5.3 TroubleshootingRefer the below table when you have troubles.

Table 4 Troubleshooting

NO. Trouble Cause Countermeasure

1 Program cannot be

installed.

Operating method not

understood

Read manual carefully

and understand it.

2 Program does not

work.

PC does not match with

required specifications.

Select suitable PC.

Available OS is Windows

XP (JP/US version)

Incorrect connection of

communication cable.

Confirm connection.

(Refer to connecting

method.)

Incorrect setting of serial

port.

Confirm setting of serial

port. COM1 is correct.

(Refer to 5.2.3)

3 PC cannot

communicate with

ECU.

ECU is not powered ON. Confirm ignition switch is

turned ON.

4 Cannot write data to

ECU or read data fromECU.

(DataExchange

function does not

work.)

The Engine is running. Perform DataExchange

when engine is notrunning but ignition switch

is ON.

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05 fi cal tool manual

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